VIRTUAL PRODUCT DEVELOPMENT DAY

FRIDAY 9TH NOVEMBER, TECHNICAL UNIVERSITY OF DENMARK

Motivation for Virtual Product Development Day

Fundamental the i4.0 transformation is the digital representation through models of the
different phases of the product value chain, including part design, manufacturing and assembly.
In the future, the development of advanced modelling solutions, in combination with sensors
data from processes and systems, is expected to lead to real time modelling as well as real time
production optimization and correction.

Programme:

Time

Schedule/Event

08:30

Registration & Coffee

09:00

Opening introduction

Prof. Jesper Hattel, Head of Section of Manufacturing Engineering, DTU-MEK

The use of virtual platforms for product development is an inherent part of the ongoing digitalization of production. The overall need for making digital twins for the entire process chain of manufacturing as well as the in-service situation will shortly be addressed, thus setting the scene for the rest of the day's presentations.

09:30

Integrated modeling of the casting and heat treatment process chain - current trends and examples from German industry

Integrated modeling of subsequent manufacturing steps is a growing field in industry. This is particularly the case for cast and heat treated parts where stress analysis is used for process optimization to provide improved solutions in casting design and product quality. Recent examples with trends from the German automotive industry and a small look into the background of the applied methods will be given.

10:10

Break

10:30

Modelling the effects of manufacturing induced microstructure and residual stresses in mechanical performance of large Ductil Cast Iron (DCI) parts

Integrated Design of Material, Manufacturing, Process and Product

11:50

Lunch

13:00

Virtual product development at LEGO with digital twins

At LEGO the use of digital twins is an inherent part of product development. This primarily includes the injection moulding manufacturing process of LEGO elements, such as filling of moulds. It also includes manufacturing processes outside regular injection moulding. In addition, the subsequent loading situations in service of both moulded elements as well as moulds, is also represented with a digital twin by need. Examples of this and additional possibilities for the use of digital twin will be given in the presentation.

13:40

Extracting fast digital twins from high fidelity models

Digital development tools and virtual prototypes are used in product development from the concept phase to virtual tests. The next natural step is to incorporate existing knowledge in the companies in digital twins. The weightings between accuracy and fast calculations in the different phases are considerably different. In the concept phase it is vital to describe all important details whereas during in-service where predictive maintenance might be the goal, digital twins with the ability to react in real time are needed.